Gantry Picking of Flat-Pack Articles From Source Pallets
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Solution Overview
Problem
Existing automatic picking systems are not suitable for picking flat-pack articles efficiently, as they often require manual handling, are not designed for direct picking from source pallets, and have low throughput due to complex conveyor networks and insufficient change cycles in high-bay warehouses.
Innovation Solution
A system comprising a rack with conveyors and gantry robots that allow direct and efficient transfer of flat-pack articles from source pallets to target pallets, decoupling the packing process from source pallet exchange, using a packing-position feeding conveyor to supply articles dynamically and statically, and arranging gantry robots and conveyors to minimize transport paths and increase throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If articles are separated from source pallets and stacked to form towers before picking, then the picking process can be automated, but the throughput is reduced and the system becomes more complex
Solution Approach 1:
The patent extracts the depalletizing function from the picking system by using a separate depalletizing robot that removes articles from source pallets and places them on a conveyor. This allows the picking gantry robot to focus solely on selecting and placing articles onto target pallets, eliminating the need to build and dismantle article towers, thereby increasing throughput while maintaining full automation.
Solution Approach 2:
The system segments the picking process into distinct functional modules: a depalletizing robot handles source pallet processing, a conveyor system transports articles, and a picking gantry robot performs order-specific selection. This modular segmentation allows each component to operate independently and efficiently, improving overall system throughput compared to integrated tower-based systems.
2Volume of stationary object
If a high-bay warehouse with storage machines is used to store source pallets, then space utilization is improved, but the number of change cycles is insufficient for efficient picking
Solution Approach 1:
The patent introduces an intermediary conveyor system that connects the high-bay warehouse storage locations to the picking position. This conveyor acts as a buffer and transport mediator, allowing source pallets to be quickly delivered to the picking station without requiring the storage machines to perform frequent change cycles. The conveyor system decouples the storage function from the picking rhythm, enabling high-speed picking while maintaining efficient space utilization.
3Ease of operation
If complex conveyor networks are used to transport articles from storage to picking positions, then article delivery is enabled, but the system complexity increases and throughput decreases
Solution Approach 1:
The patent extracts the article transport function from complex conveyor networks and implements a simplified single-conveyor system. The conveyor runs directly from the source pallet position to the picking position, eliminating intermediate transfer points, switches, and junctions. This extraction of the transport function to a simple linear conveyor reduces system complexity while maintaining effective article delivery capability.
4Productivity
If direct picking from source pallets to target pallets is implemented, then throughput is increased, but the system requires sophisticated robot positioning and control
Solution Approach 1:
The patent introduces an article conveyor as an intermediary between the source pallet and the picking position. This conveyor mediates the article flow, presenting articles in a controlled sequence to the picking gantry robot. The intermediary conveyor simplifies the robot's positioning requirements by providing a stable, moving reference frame, enabling direct picking with high throughput while reducing the complexity of robot control compared to systems requiring precise positioning relative to static pallets.
Data Source
AI summary
There are disclosed method and system (10) for picking of articles (12), in particular flat-pack articles (12), in accordance with picking orders, wherein the system (10) comprises: a rack (24) extending substantially along longitudinal and height directions (X, Y) of the system (10) and comprising a plurality of storage locations (30) configured to store source pallets (30); a gantry robot (36) including a manipulation unit (37) configured to transfer the articles (16); a packing position (62) configured to buffer a target pallet (34); a plurality of conveyors (38); and a control (74), which is preferably configured to determine, for each of the orders, an order-specific packing pattern for automatically packing, by the gantry robot (36), several of the articles (12) in accordance with the respective order from one or more of the source pallets (30) on a target pallet (34) in the packing position (62); wherein each of the conveyors (38) comprises a receiving position (66), which is positioned within the rack (24) and configured to receive the source pallets (30), as well as a delivering position (58), which is positioned within an action space of the gantry robot (36) and configured to provide, preferably dynamically, the source pallets (30); wherein the gantry robot (36) defines the action space, within which the manipulation unit (37) is movable and which contains the packing position (62) and the delivering positions (58) the conveyor (38); and wherein the control (74) is further configured to cause that such of the source pallets (30) are transported from the storage locations (32) via the receiving positions (66) to the delivering positions (58), which include the articles (12) required for the packing in accordance with the respective packing pattern.